CN106194273B - Article, component and method of forming an article - Google Patents

Article, component and method of forming an article Download PDF

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Publication number
CN106194273B
CN106194273B CN201610359380.7A CN201610359380A CN106194273B CN 106194273 B CN106194273 B CN 106194273B CN 201610359380 A CN201610359380 A CN 201610359380A CN 106194273 B CN106194273 B CN 106194273B
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China
Prior art keywords
article
body portion
conduit
aperture
orifice
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
CN201610359380.7A
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Chinese (zh)
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CN106194273A (en
Inventor
B.P.莱西
G.M.伊策尔
S.C.科蒂林加姆
S.杜塔
D.E.施克
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General Electric Co PLC
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General Electric Co
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Publication date
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Publication of CN106194273A publication Critical patent/CN106194273A/en
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Publication of CN106194273B publication Critical patent/CN106194273B/en
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D25/00Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
    • F01D25/08Cooling; Heating; Heat-insulation
    • F01D25/12Cooling
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12Blades
    • F01D5/14Form or construction
    • F01D5/18Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
    • F01D5/187Convection cooling
    • F01D5/188Convection cooling with an insert in the blade cavity to guide the cooling fluid, e.g. forming a separation wall
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D5/00Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
    • F01D5/12Blades
    • F01D5/14Form or construction
    • F01D5/18Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
    • F01D5/187Convection cooling
    • F01D5/188Convection cooling with an insert in the blade cavity to guide the cooling fluid, e.g. forming a separation wall
    • F01D5/189Convection cooling with an insert in the blade cavity to guide the cooling fluid, e.g. forming a separation wall the insert having a tubular cross-section, e.g. airfoil shape
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01DNON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
    • F01D9/00Stators
    • F01D9/02Nozzles; Nozzle boxes; Stator blades; Guide conduits, e.g. individual nozzles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00Processes of additive manufacturing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00Products made by additive manufacturing
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05DINDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2230/00Manufacture
    • F05D2230/30Manufacture with deposition of material
    • F05D2230/31Layer deposition
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05DINDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
    • F05D2260/00Function
    • F05D2260/20Heat transfer, e.g. cooling
    • F05D2260/201Heat transfer, e.g. cooling by impingement of a fluid

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Powder Metallurgy (AREA)

Abstract

The present invention relates to articles, components and methods of forming articles. An article (100) and a method of forming an article (100) are provided. The article (100) comprises a body portion (201) separating an inner region (203) and an outer region (205), an aperture (101) in the body portion (201), the aperture (101) fluidly connecting the inner region (203) to the outer region (205), and a conduit (103) extending from an outer surface (206) of the body portion (201) at the aperture (101) and arranged and disposed to controllably direct fluid from the inner region (203) to the outer region (205). The method comprises providing a body portion (201) separating an inner region (203) and an outer region (205), providing an aperture (101) in the body portion (201), and forming a conduit (103) over the aperture (101), the conduit (103) extending from an outer surface (206) of the body portion (201) and being arranged and disposed to controllably direct fluid from the inner region (203) to the outer region (205). The article (100) is arranged and disposed for insertion into a hot gas path component (400).

Description

Article, component and method of forming an article
Statement regarding federally sponsored research
The invention was made with government support under contract number DE-FC26-05NT42643 awarded by the department of energy. The government has certain rights in this invention.
Technical Field
The present disclosure is directed to an article, a component, and a method of forming an article. More particularly, the present invention is directed to a cooling article, a cooling member including the cooling article, and a method of forming the cooling article.
Background
Turbine systems are continually being retrofitted to increase efficiency and reduce costs. One method of increasing the efficiency of a turbine system includes increasing the operating temperature of the turbine system. To raise the temperature, the turbine system must be constructed of materials that can withstand this temperature during continued use.
In addition to changing component materials and coatings, common methods of increasing the temperature capability of turbine components include the use of cooling features. For example, one cooling feature includes an impingement member having an orifice formed therein. The impingement member directs the cooling fluid through the apertures and toward the surface intended to be cooled. However, once the cooling fluid flows out of the orifice, it is often difficult to control the cooling fluid flow, particularly in the presence of cross flow between the impingement member and the surface to be cooled. Further, the various components generally include portions that may be difficult to reach with the flow of cooling fluid from the impingement member.
To ensure adequate cooling of the components, an increased amount of cooling fluid is typically passed through orifices in the impingement member. When cooling fluid is typically provided from compressed air in a turbine engine, an increased amount of cooling fluid is passed through the apertures to remove an increased portion of the compressed air before reaching the combustor. Removing the added portion of the compressed air may reduce efficiency and increase operating costs of the turbine engine.
Disclosure of Invention
In an embodiment, an article includes a body portion separating an inner region and an outer region, an aperture in the body portion fluidly connecting the inner region to the outer region, and a conduit extending from an outer surface of the body portion at the aperture and arranged and disposed to controllably direct fluid from the inner region to the outer region.
In another embodiment, a component includes an article arranged and disposed to direct a fluid toward an inner surface of the component. The article includes a body portion separating an inner region and an outer region, an aperture in the body portion fluidly connecting the inner region to the outer region, and a conduit extending from an outer surface of the body portion at the aperture and arranged and disposed to controllably direct fluid from the inner region to the outer region.
In another embodiment, a method of forming an article includes providing a body portion separating an inner region and an outer region, providing an orifice in the body portion, the orifice fluidly connecting the inner region to the outer region, and forming a conduit over the orifice, the conduit extending from an outer surface of the body portion at the orifice and arranged and disposed to controllably direct fluid from the inner region to the outer region. The article is arranged and disposed for insertion into a hot gas path component of a turbine engine.
Technical solution 1. an article, comprising:
a body portion separating the inner region and the outer region;
an aperture in the body portion fluidly connecting the inner region to the outer region; and
a conduit extending from an outer surface of the body portion at the orifice and arranged and disposed to controllably direct fluid from the inner region to the outer region.
The article of claim 1, wherein the article further comprises at least one additional orifice in the body portion fluidly connecting the inner region to the outer region.
The article of claim 3. the article of claim 2, wherein the article further comprises at least one additional conduit, each of the at least one additional conduit formed over one of the at least one additional orifice.
Solution 4. the article of solution 1, wherein the conduit continues the shape of the orifice.
Solution 5 the article of claim 1, wherein the conduit is arranged and disposed to alter the fluid flow from the orifice.
The article of claim 1, wherein the article comprises an impingement member arranged and disposed for insertion within a turbine nozzle.
Solution 7. the article of solution 1, wherein the tube further comprises an aperture feature opposite the outer surface of the article, the aperture feature selected from the group consisting of a constriction in the tube, a plurality of exit apertures formed through the tube, and combinations thereof.
Solution 8. a component, wherein the component comprises the article of solution 1 arranged and disposed to direct a fluid toward an inner surface of the component.
Claim 9 the component of claim 8, wherein the conduit of the article directs fluid flow from the orifice to a hot spot on the component.
Solution 10. a method of forming an article, the method comprising:
providing a body portion separating an inner region and an outer region;
providing an aperture in the body portion, the aperture fluidly connecting the inner region to the outer region; and
forming a conduit over the orifice, the conduit extending from an outer surface of the body portion at the orifice and arranged and disposed to controllably direct fluid from the inner region to the outer region;
wherein the article is arranged and disposed for insertion into a hot gas path component of a turbine engine.
The method of claim 11, 10, wherein providing the body portion includes forming the body portion, and providing the aperture includes forming the aperture in the body portion.
The method of claim 12, 11, wherein at least one of forming the body portion, forming the orifice, and forming the conduit comprises additive manufacturing.
The method of claim 13, 11, wherein the method further comprises forming at least one additional orifice in the body portion, and forming at least one additional conduit on an outer surface of the body portion at the at least one additional orifice.
Claim 14 the method of claim 10, wherein forming the conduit over the orifice comprises arranging and setting the conduit to alter the flow of fluid from the orifice.
The method of claim 14, wherein the duct is arranged and disposed to direct the flow of cooling air from the orifice toward a hot spot of the hot gas path component.
Other features and advantages of the present invention will be apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
Drawings
Fig. 1 is a perspective view of an article according to an embodiment of the present disclosure.
Fig. 2 is a cross-sectional view of an article according to an embodiment of the present disclosure.
Fig. 3 is a cross-sectional view of an article positioned within a component according to an embodiment of the present disclosure.
Fig. 4 is an enlarged view of an article according to an embodiment of the present disclosure.
Fig. 5 is a process diagram of a method for forming an article according to an embodiment of the present disclosure.
Fig. 6 is a schematic illustration of a method for forming an article according to an embodiment of the present disclosure.
Fig. 7 is a cross-sectional view of an article according to an embodiment of the present disclosure.
Fig. 8 is a cross-sectional view of an article according to an embodiment of the present disclosure.
Fig. 9 is a cross-sectional view of an article according to an embodiment of the present disclosure.
Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
Detailed Description
An article, a component, and a method of forming an article are provided. For example, embodiments of the present disclosure provide for increased cooling efficiency, reduced cooling fluid usage, increased control of fluid flow, providing fluid flow to hard-to-reach areas, increased heat transfer, use of facilitated elevated operating temperatures, providing for fluid flow concentration at hot spots, and combinations thereof, as compared to concepts that do not include one or more features disclosed herein.
The article 100 includes any suitable article for directing fluid flow within a turbine component. In one embodiment, as shown in fig. 1, article 100 includes one or more apertures 101 formed therein. For example, in another embodiment, article 100 includes an impingement sleeve having a plurality of orifices 101. Although primarily described herein with reference to an impingement sleeve, one skilled in the art will appreciate that the article 100 may comprise any other suitable article, such as, but not limited to, an impingement plate, a plurality of impingement plates, any other cooling article, or a combination thereof.
Turning to fig. 2, an orifice 101 is formed in the body portion 201, the body portion 201 defining and/or separating an inner region 203 and an outer region 205. The orifice 101 fluidly connects the inner region 203 to the outer region 205, thereby providing fluid flow between the inner region 203 and the outer region 205. For example, in one embodiment, the apertures 101 extend between the inner surface 204 and the outer surface 206 of the body portion 201 to facilitate the flow of cooling fluid from the inner region 203 to the outer region 205.
Each orifice 101 includes any suitable geometry for fluidly connecting inner region 203 and outer region 205. Suitable geometries include, but are not limited to, circular, generally annular, circular, generally circular, elliptical, non-circular, square, triangular, star-shaped, polygonal, teardrop-shaped, varied, irregular, any other geometry, or combinations thereof. The geometry of the apertures 101 may be uniform, substantially uniform, or varying throughout the article 100, with the geometry of each aperture 101 being the same, substantially the same, and/or different than one or more other apertures 101 in the article 100. Further, apertures 101 include any suitable orientation and/or spacing that facilitates cooling flow. Suitable spacing between orifices 101 includes, but is not limited to, uniform, consistent, varying, graded, and/or segmented, wherein the spacing of each orifice 101 is the same, substantially the same, and/or different than one or more other orifices 101.
The geometry and/or spacing of the orifices 101 at least partially determines the cooling profile of the article 100. The cooling profile relates to parameters of the fluid flow through the article 100, such as, but not limited to, the concentration, distribution, and/or rate of the fluid flow through the orifice 101. For example, in one embodiment, increasing the number of apertures 101 and/or decreasing the spacing between apertures 101 increases the amount and/or concentration of cooling flow in a particular section. In another embodiment, a change in the size of the apertures 101 changes the amount of cooling flow through each aperture 101 and/or changes the rate of fluid flow through each aperture 101. In further embodiments, varying the geometry and/or spacing of the apertures 101 along the article 100 varies the cooling profile throughout the outer region 205.
Referring to fig. 1-2, the article 100 further includes one or more conduits 103 extending from the outer surface 206 of the body portion. Each conduit 103 is positioned at one of the orifices 101 to controllably direct fluid from the inner region 203 to the outer region 205. For example, in one embodiment, an opening in the conduit 103 is aligned or substantially aligned with the orifice 101 to controllably direct fluid flowing through the orifice 101 into the outer region 205. The article 100 includes any suitable number of conduits 103 in an amount equal to the number of orifices 101. Although shown as including three rows of tubes 103, one skilled in the art will recognize that the article 100 may include an increased or decreased number of tubes 103, the number of tubes 103 being equal to or less than the number of apertures 101.
The interior and/or exterior surfaces of each conduit 103 comprise any suitable cross-sectional geometry. The cross-sectional geometries of the inner and/or outer surfaces may be the same, substantially the same, or different from each other and/or the geometry of the orifice 101. Suitable geometries are consistent, substantially consistent, or vary throughout the article 100 and include, but are not limited to, circular, substantially circular, non-circular, star-shaped, oval, square, triangular, polygonal, teardrop-shaped, varying, irregular, any other geometry, or combinations thereof. For example, in one embodiment, as shown in fig. 3, the conduit 103 includes a circular or substantially circular cross-sectional geometry 301 that continues the geometry of the orifice 301. In another embodiment, conduit 103 includes a non-circular geometry, such as a star-shaped cross-sectional geometry 303, that continues the non-circular geometry of orifice 101. Alternatively, the circular, substantially circular, non-circular, and/or other cross-sectional geometries of conduit 103 may be different than the geometry of orifice 101, such as, for example, a non-circular conduit positioned over a circular or substantially circular orifice. Other aspects of the conduit 103 (such as, but not limited to, length, diameter, spacing, and/or angle) are the same, substantially the same, or different than the corresponding aspects of the orifice 101, and may be consistent, substantially consistent, or varying throughout the article 100.
The one or more conduits 103 are configured to maintain, continue, and/or alter the flow of fluid from the orifice 101. The configuration of the conduit 103 is selected to provide the desired impingement flow and/or cooling. For example, in one embodiment, the conduit 103, which has the same or substantially the same geometry as the orifice 101, continues the orientation of the orifice 101 to maintain fluid flow through at least a portion of the outer region 205. In another embodiment, the conduit 103 is oriented differently than the orifice 101 to change the direction of fluid flow from the orifice 101. In further embodiments, a conduit 103 having a different geometry than the orifice 101 alters the profile and/or direction of fluid flow from the orifice 101. In addition or alternatively, the conduit 103 may include an aperture feature 305 opposite the outer surface 206 of the article 100. The orifice feature 305 includes any suitable feature for altering the flow of fluid out of the conduit 103, such as, but not limited to, a constriction (e.g., a notch and/or partial closure), a plurality of orifices formed in the conduit 103, a narrowing (e.g., funnel-shaped), or a combination thereof.
Turning to fig. 4, in one embodiment, the article 100 is configured for insertion and/or positioning within a member 400. When inserted and/or positioned within the member 400, the outer region 205 of the article 100 extends between the outer surface 206 of the article and the inner surface 404 of the member 400. Further, the fluid flow through the apertures 101 provides impingement cooling of the component 400 when the article 100 is inserted and/or positioned within the component 400. For example, a cooling fluid provided to the inner region 203 of the article 100 may pass through the apertures 101 and/or the conduits 103 to the outer region 205 where the cooling fluid contacts the inner surface 404 of the component 400 to cool the component 400. The orientation and/or spacing of apertures 101 and/or conduits 103 at least partially determine the amount, direction, and/or concentration of cooling fluid passing from inner region 203 to outer region 205.
By maintaining, continuing, and/or varying the fluid flow from the orifice 101, the conduit 103 increases the cooling efficiency of the article 100, provides a reduced amount of fluid to the cooling of the component 400, and/or facilitates the use of elevated operating temperatures. For example, by having the fluid outlet extend from the aperture 101 at the outer surface 206 of the article 100 to the end of the conduit 103 opposite the outer surface 206, the conduit 103 provides a distance between the fluid outlet and the inner surface 404 of the member 400 independent of the size of the body portion 201. In one embodiment, the conduit 103 allows for the use of a relatively smaller body portion 201 that increases the size of the outer region 205 between the outer surface 206 of the body portion 201 and the inner surface 404 of the member 400. In another embodiment, the increased size of the outer region 205 reduces the cross-flow velocity in the outer region 205. The reduced cross-flow velocity in outer region 205 reduces the effect of cross-flow on the impinging fluid flow, facilitates enhanced control of the impinging fluid flow, increases cooling efficiency, and/or facilitates cooling with a reduced amount of fluid.
Additionally or alternatively, the conduit 103 reduces the distance between the fluid outlet and the inner surface 404 of the member 400. The reduced distance between the fluid outlet and the inner surface 404 of the member 400 reduces the exposure of the fluid to cross flow within the outer region 205 and/or increases the contact between the fluid and the inner surface 404, which improves cooling efficiency. Additionally or alternatively, the duct 103 may be oriented to direct and/or focus fluid flow toward a particular portion of the component 400, such as, but not limited to, a hot spot, a hot side wall of the component 400, a hard-to-reach portion including a trailing edge portion of a turbine nozzle (see fig. 1-2), or a combination thereof. Reducing the distance between the fluid outlets of the conduits 103 and/or directing and/or focusing the fluid flow through the conduits 103 facilitates using a reduced amount of fluid flow, improves the cooling efficiency of the cooling fluid as compared to the individual apertures 101, facilitates higher temperature operation of the component 400, increases throughput, and/or improves operating efficiency.
In one embodiment, forming article 100 and/or pipe 103 comprises any suitable additive manufacturing method. Referring to fig. 5-6, in another embodiment, additive method 500 includes producing and/or forming a net-shape or near-net-shape article 100 and/or pipe 103. The phrase "near net shape" as used herein means that article 100 and/or pipe 103 are formed with a geometry and dimensions that are very similar to the final geometry and dimensions of article 100 and/or pipe 103, with little or no machining and processing required after additive process 500. The phrase "net shape" as used herein means that the article 100 and/or the conduit 103 are formed with a geometry and dimensions that do not require machining and handling. For example, in one embodiment, additive method 500 includes producing article 100 including one or more orifices 100 and/or one or more conduits 103. Additive method 500 provides any net or near net shape to article 100, orifice 101, and/or conduit 103. Additionally or alternatively, additive method 500 includes forming article 100 separate from the one or more conduits 103, and then securing the one or more conduits 103 to article 100. Although described with reference to apertures 101 formed during additive method 500, as one skilled in the art will recognize, at least one aperture 101 may be machined into article 100 after additive method 500 without affecting the net-shape or near-net-shape geometry of article 100.
Additive method 500 includes any manufacturing method that forms article 100 and/or conduit 103 by sequentially and repeatedly depositing and joining layers of material. Suitable fabrication methods include, but are not limited to, processes known to those of ordinary skill in the art as Direct Metal Laser Melting (DMLM), Direct Metal Laser Sintering (DMLS), laser engineered net shaping, Selective Laser Sintering (SLS), Selective Laser Melting (SLM), Electron Beam Melting (EBM), Fused Deposition Modeling (FDM), or combinations thereof. In one embodiment, for example, additive method 500 includes providing metal alloy powder 601 (step 501); forming an initial layer 602 using the metal alloy powder 601 (step 502); sequentially forming an additional layer 622 on the initial layer 602 using the metal alloy powder 601 (step 503); and bonding the additional layer 622 to the initial layer 602 to form the article 100 and/or the conduit 103 (step 504). In another embodiment, additive method 500 includes repeating the steps of: additional layer 622 is formed sequentially over the previously formed layers, and additional layer 622 is bonded to the previously formed layers (step 505) until article 100 and/or conduit 103 having a predetermined thickness and/or a predetermined shape is obtained. The previously formed layers include any portion 611 of the article 100 and/or the pipe 103 that includes the initial layer 602 and/or any other additional layer 622 directly or indirectly joined to the initial layer 602.
The initiation layer 602 includes a preselected thickness 603 and a preselected shape that includes at least one first opening 604. Each additional layer 622 includes a second preselected thickness 623 and a second preselected shape that includes at least one second opening 624 that corresponds to the at least one first opening 604 in the initial layer 602. The second preselected thickness 623 and/or the second preselected shape can be the same, substantially the same, or different between the one or more additional layers 622. When joined, the preferred thickness 603 of the initial layer 602 and the second preselected thickness 623 of the additional layer 622 form a combined thickness 633 of the portion 611. In addition, the at least one first opening 604 and the corresponding at least one second opening 624 form one or more combined openings 634 in the portion 611. Once the article 100 is formed, the one or more combined openings 634 form one or more apertures 101 that fluidly connect the inner region 203 to the outer region 205 of the portion 611.
In one embodiment, additive method 500 includes a DMLM process. In another embodiment, the DMLM process includes providing a metal alloy powder 601 and depositing the metal alloy powder 601 to form an initial powder layer. The initial powder layer has a preselected thickness 603 and a preselected shape that includes at least one first opening 604. In another embodiment, the DMLM process includes providing a focused energy source 610, and directing the focused energy source 610 at the preliminary powder layer to melt the metal alloy powder 601 and transform the preliminary powder layer into the portion 611 of the article 100 and/or the conduit 103. Suitable energy sources include, but are not limited to, laser devices, electron beam devices, or combinations thereof.
Next, the DMLM process includes sequentially depositing additional metal alloy powder 601 on the article 100 and/or the portion 611 of the conduit 103 to form an additional layer 622 having a second preselected thickness 623 and a second preselected shape that includes at least one second opening 624 that corresponds to the at least one first opening 604 in the starting powder layer 602. After depositing the additional layer 622 of metal alloy powder 601, the DMLM process includes melting the additional layer 622 with the focused energy source 610 to increase the combined thickness 633 and form at least one combined opening 634 having a predetermined profile.
The steps of sequentially depositing additional layers of metal alloy powder 601 and melting additional layer 622 may then be repeated to form the net-shape or near-net-shape article 100 and/or the conduit 103. For example, the steps may be repeated until an article 100 having a predetermined thickness, a predetermined shape, and one or more orifices 101 having any suitable geometry is obtained. Further, the steps may be repeated to form one or more conduits 103 directly over at least one of the one or more orifices 101. In one embodiment, one or more conduits 103 include support members configured to provide support during additive method 500. The support members may form a portion of the article 100 or may be removed after formation to form the article 100 without, or substantially without, the support members.
As discussed in detail above, and as shown in fig. 7-9, the conduit 103 is perpendicular to the body portion 201 and/or angled with respect to the body portion 201, and may be formed to maintain, continue, and/or alter the fluid flow from the orifice 101. For example, as shown in fig. 7, the conduit 103 extends the orientation and cross-sectional geometry of the orifice 101. In another example, as shown in fig. 8, the conduit 103 is angled relative to the body portion 201, the angle of the conduit 103 maintaining the cross-sectional geometry while changing the orientation of the orifice 101. The angle may also be selected to provide support during additive manufacturing of the article 100. Suitable angles for changing the orientation of orifice 101 and/or providing support during additive manufacturing include, but are not limited to, between 1 ° and 179 °, between 30 ° and 150 °, between 1 ° and 90 °, between 45 ° and 135 °, between 30 ° and 90 °, between 90 ° and 150 °, between 45 ° and 90 °, between 90 ° and 135 °, about 45 °, about 90 °, about 135 °, or any combination, sub-combination, range, or sub-range thereof. Additionally or alternatively, as shown in fig. 9, the cross-sectional geometry of conduit 103 may be different than the cross-sectional geometry of orifice 101.
In one embodiment, additive method 500 includes forming a hole feature 305 on pipe 103. In another embodiment, the conduits 103 and the aperture features 305 are formed during the formation of the article 100. In addition or alternatively, the conduits 103 and/or the aperture features 305 may be formed separately from and/or after the formation of the article 100. For example, the conduit 103 and/or the aperture feature 305 may be formed directly on a previously formed article 100 using the additive method 500, or the conduit 103 and/or the aperture feature 305 may be formed separately from the article 100 and then attached to the article 100. Forming the conduit 103 and/or the bore feature 305 separately from the article 100 may include an additive process 500 or a non-additive process, such as machining and/or casting.
While the invention has been described with reference to one or more embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. Moreover, all numbers expressing quantities of ingredients, and so forth used in the detailed description are to be understood as being indicative of both the exact and approximate values explicitly indicated.

Claims (15)

1. A cooling article (100) comprising:
a body portion (201) separating an inner region (203) and an outer region (205);
an aperture (101) in the body portion (201), the aperture (101) fluidly connecting the inner region (203) to the outer region (205); and
a conduit (103) extending from an outer surface (206) of the body portion (201) at the orifice (101) and arranged and disposed to controllably direct fluid from the inner region (203) to the outer region (205);
wherein the conduit has an orientation or cross-sectional shape that is different from an orientation or cross-sectional shape of the orifice.
2. The cooling article (100) of claim 1, wherein the cooling article (100) further comprises at least one additional aperture (101) in the body portion (201), the at least one additional aperture (101) fluidly connecting the inner region (203) to the outer region (205).
3. The cooling article (100) of claim 2, wherein the cooling article (100) further comprises at least one additional duct (103), each of the at least one additional duct (103) being formed on one of the at least one additional aperture (101).
4. The cooling article (100) according to claim 1, wherein the duct (103) continues the shape of the orifice (101).
5. The cooling article (100) of claim 1, wherein the conduit (103) is arranged and disposed to alter a fluid flow from the orifice (101).
6. The cooling article (100) of claim 1, wherein the cooling article (100) comprises an impingement member arranged and disposed for insertion within a turbine nozzle.
7. The cooling article (100) of claim 1, wherein the duct (103) further comprises a hole feature (305) opposite the outer surface (206) of the cooling article (100), the hole feature (305) being selected from the group consisting of a constriction in the duct (103), a plurality of outlet holes formed through the duct (103), and combinations thereof.
8. A cooling member (400), wherein the cooling member (400) comprises a cooling article (100) according to claim 1, the cooling article (100) being arranged and disposed to direct a fluid towards an inner surface (204) of the cooling member (400).
9. The cooling member (400) of claim 8, wherein the duct (103) of the cooling article (100) directs a fluid flow from the aperture (101) to a hot spot on the cooling member (400).
10. A method of forming a cooling article (100), the method comprising:
providing a body portion (201) separating an inner region (203) and an outer region (205);
providing an aperture (101) in the body portion (201), the aperture (101) fluidly connecting the inner region (203) to the outer region (205); and
forming a conduit (103) over the aperture (101), the conduit (103) extending from an outer surface (206) of the body portion (201) at the aperture (101) and being arranged and disposed to controllably direct fluid from the inner region (203) to the outer region (205);
wherein the cooling article (100) is arranged and disposed for insertion into a hot gas path component (400) of a turbine engine.
11. The method of claim 10, wherein providing the body portion (201) comprises forming the body portion (201), and providing the aperture (101) comprises forming the aperture (101) in the body portion (201).
12. The method of claim 11, wherein at least one of forming the body portion (201), forming the orifice (101), and forming the conduit (103) comprises additive manufacturing.
13. The method of claim 11, further comprising forming at least one additional orifice (101) in the body portion (201), and forming at least one additional conduit (103) on an outer surface (206) of the body portion (201) at the at least one additional orifice (101).
14. The method of claim 10, wherein forming the conduit (103) over the orifice (101) comprises arranging and disposing the conduit (103) to alter a fluid flow from the orifice (101).
15. The method according to claim 14, wherein the duct (103) is arranged and disposed to direct a flow of cooling air from the aperture (101) towards a hot spot of the hot gas path component (400).
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US9976441B2 (en) 2018-05-22

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